KR20250144508A - Aerosol-forming cartridge comprising a tobacco-containing material - Google Patents

Abstract

An aerosol-forming cartridge (220) for use in an electrically operated aerosol-generating system is provided. The cartridge (220) comprises a base layer (222) and at least one aerosol-forming substrate (224) disposed on the base layer (222) and comprising a tobacco-containing material having volatile tobacco flavor compounds that are releasable from the aerosol-forming substrate (224). The base layer (222) and the at least one aerosol-forming substrate (224) are in contact at a substantially planar contact surface.

Description

Aerosol-forming cartridge comprisin a tobacco-containing material {AEROSOL-FORMING CARTRIDGE COMPRISING A TOBACCO-CONTAINING MATERIAL}

The present invention relates to an aerosol-forming cartridge for use in an electrically operated aerosol-generating system. In particular, the present invention relates to an aerosol-forming cartridge comprising at least one aerosol-forming substrate comprising a tobacco-containing material having volatile tobacco flavor compounds that can be released from the aerosol-forming substrate. The present invention also relates to an aerosol-generating system comprising the aerosol-forming cartridge and a method for making the aerosol-forming cartridge.

One type of aerosol-generating system is an electrically operated smoking system. Portable electrically operated smoking systems are known, comprising an electric vaporizer, an aerosol-generating device including a battery and control electronics, and an aerosol-forming cartridge. Typically, an aerosol-forming cartridge for use with an aerosol-generating device comprises an aerosol-forming substrate, often assembled into a rod shape, together with other components or parts. Typically, the rod is shaped and sized to be inserted into an aerosol-generating device that includes a heating element for heating the aerosol-forming substrate. Other known aerosol-forming cartridges include an aerosol-forming substrate in contact with or in proximity to an electric heater forming part of the cartridge. In one such example, the cartridge comprises a supply portion of a liquid aerosol-forming substrate and a coil of heater wire wound around a thin, elongated wick immersed in the liquid aerosol-forming substrate. Known cartridges typically include a mouthpiece portion that a user inhales during use to draw the aerosol into the mouth.

However, known aerosol-forming cartridges are relatively expensive to manufacture. This is due to their complexity and the fact that their manufacture typically requires extensive manual assembly work. Furthermore, to prevent damage during transport, these cartridges often require careful handling or the provision of a protective outer housing.

EP-A2-0271036 provides a smoking article comprising a combustible heat source, an aerosol-forming agent contained within a capsule downstream of the heat source, and a mouthpiece downstream of the aerosol-forming agent. The capsule comprises a metal tube containing the aerosol-forming agent within the capsule. The capsule is joined to the heat source and the mouthpiece by a cigarette paper, forming an integral part of the smoking article. Therefore, when the flavor source is consumed, the capsule cannot be separated from the rest of the smoking article. Instead, when the flavor source is consumed, the entire smoking article is disposed of as a single unit.

US-A1-2008/092912 provides a smoking article having an aerosol-forming cartridge containing tobacco material, housed within an aerosol-generating device. The cartridge is rod-shaped.

It would be desirable to provide aerosol forming cartridges that are robust and inexpensive to manufacture.

According to a first aspect of the present invention, there is provided an aerosol-forming cartridge for use in an electrically operated aerosol-generating system, comprising: a base layer; and at least one aerosol-forming substrate disposed on the base layer and comprising a tobacco-containing material having volatile tobacco flavor compounds that are releasable from the aerosol-forming substrate, wherein the base layer and the at least one aerosol-forming substrate are in contact at a substantially planar contact surface.

By contacting the base layer and at least one aerosol-forming substrate at a substantially planar contact surface, the cartridge can advantageously be manufactured using only vertical assembly operations. This simplifies the manufacture of the cartridge by eliminating the need for more complex assembly operations, such as rotation or multiple translational movements of the cartridge or its components, as is known in the manufacture of cylindrical objects such as cigarettes. Such cartridges can also be manufactured using fewer parts than conventional cartridges and are generally more robust.

Figures 1a, 1b and 1c illustrate schematic diagrams of an aerosol generating system comprising an aerosol forming cartridge according to the present invention inserted into an electrically operated aerosol generating device.
Figures 2a and 2b illustrate a first embodiment of an aerosol forming cartridge according to the present invention, wherein Figure 2a is a perspective view of the cartridge and Figure 2b is an exploded view of the cartridge.
Figures 3a and 3b illustrate a second embodiment of an aerosol forming cartridge according to the present invention, wherein Figure 3a is a perspective view of the cartridge and Figure 3b is an exploded view of the cartridge.
Figures 4a and 4b illustrate a third embodiment of an aerosol forming cartridge according to the present invention, wherein Figure 4a is a perspective view of the cartridge and Figure 4b is an exploded view of the cartridge.
Figure 5 illustrates a schematic diagram of a manufacturing process for manufacturing the aerosol forming cartridge of Figures 2a and 2b.
Figure 6 illustrates a schematic diagram of a manufacturing process for manufacturing the aerosol forming cartridge of Figures 3a and 3b.

As used herein, the term “cartridge” refers to a consumable that is configured to be coupled to and separated from an aerosol-generating device to form an aerosol-generating system, and that is also assembled as a single unit that can be coupled to and separated from the aerosol-generating device by a user when the article is consumed.

As used herein, the term "aerosol-forming cartridge" refers to a cartridge comprising an aerosol-forming substrate capable of releasing a volatile compound capable of forming an aerosol. For example, the aerosol-generating cartridge may be a smoking article.

As used herein, the term "aerosol-forming substrate" is used to describe a substrate capable of releasing volatile compounds capable of forming an aerosol. The aerosol generated from the aerosol-forming substrate of a smoking article according to the present invention may be visible or invisible and may include vapors (e.g., particulate matter in a gaseous state that is normally liquid or solid at room temperature), as well as droplets of gas and condensed vapors.

As used herein, the term “contact” includes direct contact between two components of a cartridge as well as indirect contact through one or more intermediate components of the cartridge, such as a coating or laminated layer.

As used herein, the term “substantially planar” means arranged substantially along a single plane.

Preferably, the aerosol-forming cartridge is a heated smoking article comprising an aerosol-forming substrate that is intended to be heated rather than combusted to release volatile compounds capable of forming an aerosol.

The cartridge may have any suitable external shape. The cartridge may be an elongated aerosol-forming cartridge having a downstream end through which the aerosol exits the aerosol-generating cartridge and an opposite upstream end through which the aerosol is delivered to the user. In such embodiments, components, or portions of components, of the aerosol-forming substrate may be described as being upstream or downstream of each other based on the relative positions between the proximal or downstream end and the distal or upstream end. Preferably, the cartridge is substantially flat. In certain embodiments, the cartridge is substantially flat and has a rectangular cross-section.

The cartridge may have any suitable size. Preferably, the cartridge has dimensions suitable for use with a portable aerosol-generating system. In certain embodiments, the cartridge has a length of from about 5 mm to about 200 mm, preferably from about 10 mm to about 100 mm, and more preferably from about 20 mm to about 35 mm. In certain embodiments, the cartridge has a width of from about 5 mm to about 12 mm, preferably from about 7 mm to about 10 mm. In certain embodiments, the cartridge has a height of from about 2 mm to about 10 mm, preferably from about 5 mm to about 8 mm.

Preferably, at least one aerosol-forming substrate is substantially flat. As used herein, the term "substantially flat" means having a thickness-to-width ratio of at least 1:2, preferably from 1:2 to about 1:20. This includes, but is not limited to, having a substantially planar shape. Flat components can be easily handled during manufacturing and provide a robust structure. Furthermore, it has been found that aerosol release from the aerosol-forming substrate is enhanced when the substrate is substantially flat and when airflow is drawn through the width, length, or both of the width and length of the aerosol-forming substrate.

In certain embodiments, one or both of the base layer and the at least one aerosol-forming substrate have a non-curved cross-section. This reduces the rolling motion of these components during manufacturing, thereby improving assembly precision and ease of assembly. In certain embodiments, one or both of the base layer and the at least one aerosol-forming substrate are substantially planar.

The term “base layer” refers to the layer of the cartridge that supports the aerosol-forming substrate, and does not necessarily refer to the location of the layer within the cartridge. The base layer may be, but is not limited to, the lowermost layer of the cartridge.

The base layer may have any suitable cross-sectional shape. Preferably, the base layer has a non-circular cross-sectional shape. In certain preferred embodiments, the base layer has a substantially rectangular cross-sectional shape. In certain preferred embodiments, the base layer has an elongated, substantially rectangular, parallelepiped shape. In certain preferred embodiments, the base layer is substantially flat.

The aerosol-forming substrate may be disposed directly on the base layer or indirectly via one or more intermediate layers. The base layer may have a substantially planar top surface on which the aerosol-forming substrate is disposed. In a preferred embodiment, the base layer comprises at least one cavity in which at least one aerosol-forming substrate is accommodated. This helps maintain the precise position of the aerosol-forming substrate within the cartridge and, if necessary, facilitates sealing the aerosol-forming substrate within the cartridge. In certain embodiments, the at least one aerosol-forming substrate comprises multiple aerosol-forming substrates individually disposed on the base layer, and the base layer comprises multiple cavities. Thus, two or more aerosol-forming substrates can be accommodated in different cavities. If the aerosol-forming substrates have different compositions, storing them individually in separate cavities can extend the life of the cartridge. Another advantage is that this also allows the cartridge to store two or more incompatible aerosol-forming substrate materials. In certain embodiments, one or more cavities can be selectively opened from a closed position.

The base layer may be formed as a single component. Alternatively, the base layer may be formed of multiple layers or components. For example, the base layer may be formed of a first layer defining at least one side wall of the cavity and a second layer defining at least one bottom wall of the cavity.

The base layer may be formed using any suitable manufacturing method. In certain embodiments, the base layer may comprise a polymer foil. The base layer may include one or more cavities formed by one or more bubbles in the foil. The polymer foil may comprise one or more of any suitable materials, such as, but not limited to, polyimide (PI), polyether ether ketone (PEEK), polyether ketone (PEK), or polyaryletherketone (PAEK) such as polyetherketoneetherketoneketone (PEKEKK), or a fluoropolymer such as polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), ethylene tetrafluoroethylene (ETFE), PVDFELS, or fluorinated ethylene propylene (FEP). Alternatively, the base layer can be formed by injection molding of one or more of a polymeric material, such as, but not limited to, a polyaryletherketone (PAEK) such as polyether ether ketone (PEEK), polyether ketone (PEK), or polyetherketoneetherketoneketone (PEKEKK), a polyphenylene sulfide such as polyphenylene sulfide (PPS), or a polyarylsulfone such as polychlorotrifluoroethene (PCTFE or PTFCE), polysulfone (PSU), polyphenylsulfone (PPSF or PPSU), polyethersulfone (PES), or polyethyleneimine (PEI), or a fluoropolymer such as polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), ethylene tetrafluoroethylene (ETFE), PVDFELS, or fluorinated ethylene propylene (FEP).

At least one aerosol-forming substrate comprises a tobacco-containing material having volatile tobacco flavor compounds that are released from the aerosol-forming substrate upon heating.

Preferably, at least one aerosol-forming substrate comprises an aerosol former, i.e., a material that generates an aerosol upon heating. The aerosol former may be, for example, a polyol aerosol former or a non-polyol aerosol former. The aerosol former may be solid or liquid at room temperature, but is preferably liquid at room temperature. Suitable polyols include sorbitol, glycerol, and glycols such as propylene glycol or triethylene glycol. Suitable non-polyols include monohydric alcohols such as methanol, high boiling point hydrocarbons, acids such as lactic acid, and esters such as diacetin, triacetin, triethyl citrate, or isopropyl myristate. Aliphatic carboxylic acid esters such as methyl stearate, dimethyl dodecanedioate, and dimethyl tetradecanedioate may also be used as aerosol-forming agents. Combinations of aerosol formers may be used in the same or different proportions. While polyethylene glycol and glycerol may be particularly preferred, triacetin is more difficult to stabilize and may need to be encapsulated to prevent its migration within the product. Examples of suitable aerosol-forming agents include glycerin and propylene glycol. At least one aerosol-forming substrate may comprise one or more flavoring agents, such as cocoa, licorice, an organic acid, or menthol. At least one aerosol-forming substrate may comprise a solid substrate. The solid substrate may comprise one or more of powders, granules, pellets, shreds, spaghetti, strips, or sheets, for example, containing one or more of herbal leaves, tobacco leaves, tobacco rib pieces, reconstituted tobacco, homogenized tobacco, extruded tobacco, and expanded tobacco. Optionally, the solid substrate may contain additional tobacco or non-tobacco volatile flavor compounds that are released upon heating the substrate. Optionally, the solid substrate may also contain capsules, for example, containing additional tobacco or non-tobacco volatile flavor compounds. These capsules may melt during heating of the solid aerosol-forming substrate. Alternatively, or additionally, these capsules may be pulverized before, during, or after heating of the solid aerosol-forming substrate.

Where at least one aerosol-forming substrate comprises a solid substrate comprising homogenized tobacco material, the homogenized tobacco material may be formed by agglomerating particulate tobacco. The homogenized tobacco material may be in the form of a sheet. The homogenized tobacco material may have an aerosol former content of greater than 5% by dry weight. Alternatively, the homogenized tobacco material may have an aerosol former content of from 5% to 30% by dry weight. The homogenized tobacco material sheet may be formed by agglomerating particulate tobacco obtained by crushing or finely grinding one or both of the tobacco lamina and the tobacco petiole; alternatively, or additionally, the homogenized tobacco material sheet may comprise one or more of tobacco dust, tobacco fines, and other particulate tobacco by-products, for example, generated during the processing, handling, and shipping of tobacco. The homogenized tobacco material sheet may comprise one or more intrinsic binders, which are tobacco-intrinsic binders, one or more extrinsic binders, which are tobacco-extrinsic binders, or a combination thereof to aid in agglomeration of the particulate tobacco. Alternatively, or additionally, the homogenized tobacco material sheet may comprise other additives, including but not limited to, tobacco and non-tobacco fibers, aerosol formers, humectants, plasticizers, flavoring agents, fillers, aqueous and non-aqueous solvents, and combinations thereof. The homogenized tobacco material sheet is preferably formed by a type of casting process, which generally comprises casting a slurry comprising particulate tobacco and one or more binders onto a conveyor belt or other support surface, drying the cast slurry to form a homogenized tobacco material sheet, and removing the homogenized tobacco material sheet from the support surface.

Optionally, the solid substrate may be provided on or embedded in a thermally stable carrier. The carrier may take the form of a powder, granules, pellets, shreds, spaghetti, strips or sheets. Alternatively, the carrier may be a tubular carrier having a thin layer of the solid substrate disposed on its inner surface, on its outer surface, or on both its inner and outer surfaces, such as those disclosed in US-A-5 505 214, US-A-5 591 368 and US-A-5 388 594. Such a tubular carrier may be formed of, for example, paper, a paper-like material, a non-woven carbon fiber mat, a low mass open mesh metal screen, or a perforated metal foil, or any other thermally stable polymer matrix. The solid substrate may be disposed on the surface of the carrier in the form of, for example, a sheet, a foam, a gel or a slurry. The solid substrate may be placed over the entire surface of the carrier, or alternatively, may be placed in a pattern to provide a non-uniform flavor delivery during use. Alternatively, the carrier may be a non-woven fabric or fiber bundle with integrated tobacco components, such as those described in EP-A-0 857 431. The non-woven fabric or fiber bundle may comprise, for example, carbon fibers, natural cellulose fibers, or cellulose derivative fibers.

The aerosol-forming substrate may comprise a liquid substrate, and the cartridge may comprise means for holding the liquid substrate, such as one or more containers. Alternatively or additionally, the cartridge may comprise a porous carrier material into which the liquid substrate is absorbed, as described in WO-A-2007/024130, WO-A-2007/066374, EP-A-1 736 062, WO-A-2007/131449 and WO-A-2007/131450. The aerosol-forming substrate may alternatively be any other type of substrate, for example a gaseous substrate, a gel substrate, or any combination of the various types of substrates described.

At least one aerosol-forming substrate may comprise a single aerosol-forming substrate. Alternatively, the at least one aerosol-forming substrate may comprise multiple aerosol-forming substrates. The multiple aerosol-forming substrates may have substantially the same composition. Alternatively, the multiple aerosol-forming substrates may comprise two or more aerosol-forming substrates having substantially different compositions. The multiple aerosol-forming substrates may be stored together on the base layer. Alternatively, the multiple aerosol-forming substrates may be stored separately. By separately storing two or more different portions of the aerosol-forming substrate, two completely incompatible substances may be stored in the same cartridge. Advantageously, separately storing two or more different locations of the aerosol-forming substrate may extend the life of the cartridge. Furthermore, two incompatible substances may be stored in the same cartridge. Furthermore, for example, by separately heating each aerosol-forming substrate, the aerosol-forming substrates may be individually aerosolized. Thus, aerosol-forming substrates with different heating profile requirements can be heated differently to achieve improved aerosol formation. This can also enable more efficient energy use, as more volatile substances can be heated to a lower degree separately from less volatile substances. For example, by heating a different aerosol-forming substrate for each use, individual aerosol-forming substrates can be aerosolized in a predetermined order, ensuring that a "new" aerosol-forming substrate is aerosolized each time the cartridge is used.

Preferably, at least one aerosol-forming substrate is substantially flat. The at least one aerosol-forming substrate may have any suitable cross-sectional shape. Preferably, the at least one aerosol-forming substrate has a cross-sectional shape that is not circular. In a preferred embodiment, the aerosol-forming substrate has a substantially planar first surface forming a contact surface between the aerosol-forming substrate and the base layer, and a substantially planar second surface opposite the first surface, from which an aerosol can be emitted upon heating. In a particular preferred embodiment, the at least one aerosol-forming substrate has a substantially rectangular cross-sectional shape. In a particular preferred embodiment, the at least one aerosol-forming substrate has an elongated, substantially rectangular, parallelepiped shape.

In certain preferred embodiments, at least one aerosol-forming substrate has a vaporization temperature of from about 60° C. to about 320° C., preferably from about 70° C. to about 230° C.

In any embodiment of the cartridge, the preferred material or materials for each of the various cartridge components will depend on the required vaporization temperature of the aerosol forming substrate.

In use, at least one aerosol-forming substrate is vaporized by a vaporizer. The vaporizer may be provided as part of an aerosol-generating device, as part of an aerosol-forming cartridge, as a separate component, or as any combination thereof. The vaporizer may be any suitable device for vaporizing at least one aerosol-forming substrate. For example, the vaporizer may be a piezoelectric element or an ultrasonic device. Preferably, the vaporizer comprises an electric heater comprising at least one heating element configured to heat the aerosol-forming substrate.

When the aerosol-forming cartridge includes a vaporizer for vaporizing the aerosol-forming substrate, the vaporizer should be positioned on the base layer such that the contact surface between the vaporizer and the base layer is substantially planar and parallel to the contact surface between the base layer and the aerosol-forming substrate. With this arrangement, the cartridge can be manufactured using only vertical assembly operations. This simplifies the manufacture of the cartridge by eliminating the need for more complex assembly operations, such as rotation or multiple translational movements of the cartridge or its components. The vaporizer can be substantially planar. In a preferred embodiment, the vaporizer is substantially planar.

The vaporizer may be any suitable device for vaporizing the aerosol-forming substrate. For example, the vaporizer may be a piezoelectric element or an ultrasonic device, or a non-electric heater, such as a chemical heater. Preferably, the vaporizer comprises an electric heater comprising at least one heating element configured to heat the aerosol-forming substrate. In certain preferred embodiments, the cartridge further comprises an electric heater comprising at least one heating element arranged to heat the at least one aerosol-forming substrate, wherein a contact surface between the electric heater and one or both of the base layer and the at least one aerosol-forming substrate is substantially planar and substantially parallel to the contact surface between the base layer and the at least one aerosol-forming substrate.

The electric heater may be arranged to heat the aerosol-forming substrate by one or more of conduction, convection, and radiation. The heater may heat the aerosol-forming substrate by conduction and may be in at least partial contact with the aerosol-forming substrate. Alternatively, or additionally, heat from the heater may be conducted to the aerosol-forming substrate by an intermediate thermally conductive member. Alternatively, or additionally, the heater may transfer heat to ambient inlet air drawn through or past the cartridge during use, which in turn heats the aerosol-forming substrate by convection.

The heater may be an electric heater powered by a power supply. The term “electric heater” refers to one or more electric heating elements. The electric heater may include an internal electric heating element for at least partially inserting into an aerosol-forming substrate. An “internal heating element” is one suitable for insertion into an aerosol-forming material. Alternatively or additionally, the electric heater may include an external heating element. The term “external heating element” refers to one that at least partially surrounds the aerosol-forming substrate. The electric heater may include one or more internal heating elements and one or more external heating elements. The electric heater may include a single heating element. Alternatively, the electric heater may include more than one heating element. In certain embodiments, the cartridge includes an electric heater comprising one or more heating elements.

The electric heater may comprise an electrically resistive material. Suitable electrically resistive materials include, but are not limited to, semiconductors such as doped ceramics, electrically "conductive" ceramics (such as molybdenum disilicide), carbon, graphite, metals, metal alloys, and composites of ceramic and metal materials. Such composite materials may comprise doped or undoped ceramics. An example of a suitable doped ceramic includes doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum, and platinum group metals. Examples of suitable metal alloys include stainless steel, nickel-, cobalt-, chromium-, aluminum-, titanium-, zirconium-, hafnium-, niobium-, molybdenum-, tantalum-, tungsten-, tin-, gallium-, manganese-, and iron-containing alloys, and superalloys based on nickel, iron, cobalt, stainless steel, Timetal®, and iron-manganese-aluminum alloys. In the composite, depending on the desired external physicochemical properties and energy transfer kinetics, the electrically resistive material may optionally be embedded in, encapsulated in, or coated with an insulating material, or vice versa. Alternatively, the electric heater may comprise an infrared heating element, a photon source, or an induction heating element.

The electric heater may take any suitable form. For example, the electric heater may take the form of a heating blade. Alternatively, the electric heater may take the form of a casing or substrate having different electrically conductive portions, or an electrically resistant metal tube. Alternatively, the electric heater may include one or more heating needles or rods penetrating the center of the aerosol-forming substrate. Alternatively, the electric heater may be a disk (end) heater, or a combination of heating needles or rods and disk heaters. The electric heater may include one or more stamped portions of an electrically resistant material, such as stainless steel. Other alternatives include heating wires or filaments, such as Ni-Cr (nickel-chromium), platinum, tungsten, or alloy wires or heating plates.

In certain preferred embodiments, the electric heater comprises a plurality of electrically conductive filaments. The plurality of electrically conductive filaments may form a filament mesh or array, or may comprise a fabric or nonwoven fabric.

The electrically conductive filaments can define gaps between the filaments, and the gaps can have a width of from 10 μm to 100 μm. Preferably, the filaments cause capillary action in the gaps, so that the liquid to be vaporized during use is drawn into the gaps, thereby increasing the contact area between the heater assembly and the liquid. The electrically conductive filaments can form a mesh having a size of from 160 to 600 Mesh US (+/- 10%) (i.e., from 160 to 600 filaments per inch (+/- 10%)). The gap width is preferably from 25 μm to 75 μm. The percentage of open area of the mesh, which is the ratio of the gap area to the total mesh area, is preferably from 25% to 56%. The mesh can be formed using different types of weave or lattice structures. The mesh, array, or fabric of electrically conductive filaments may be characterized by their ability to retain liquid, as is well understood in the art. The electrically conductive filaments may have a diameter of from 10 μm to 100 μm, preferably from 8 μm to 50 μm, and more preferably from 8 μm to 39 μm. The filaments may have a round or flat cross-section. The heater filaments may be formed by etching a sheet material, such as a foil. This may be particularly advantageous when the heater assembly comprises an array of parallel filaments. When the heater assembly comprises a mesh or fabric of filaments, the filaments may be formed individually and then intertwined and bonded together. The electrically conductive filaments may be provided as a mesh, array, or fabric. The area of the mesh, array, or fabric of electrically conductive filaments may be small, preferably less than 25 mm ² , so as to enable inclusion in a portable system. The mesh, array or fabric of electrically conductive filaments may be, for example, rectangular and may have dimensions of 5 mm x 2 mm. Preferably, the mesh or array of electrically conductive filaments covers an area of from 10% to 50% of the area of the heater assembly. More preferably, the mesh or array of electrically conductive filaments covers an area of from 15% to 25% of the area of the heater assembly.

Optionally, the heating element may be disposed within or on the carrier material. In a preferred specific embodiment, the heating element is disposed on an electrically insulating substrate foil. The substrate foil may be flexible. The substrate foil may be polymeric. The substrate foil may be a multilayer polymeric foil. The heating element or heating elements may extend across one or more openings in the substrate foil.

In one embodiment, electrical energy is supplied to the electric heater until the heating element or elements of the electric heater reach a temperature of about 180°C to about 310°C. Any suitable temperature sensor and control circuit may be used to control the heating of the heating element or elements to reach the desired temperature. This is in contrast to conventional cigarettes, where combustion of the tobacco and cigarette wrapper can reach temperatures of 800°C.

Preferably, the minimum distance between the electric heater and at least one aerosol-forming substrate is less than 50 μm, and preferably the cartridge comprises one or more capillary fiber layers in the space between the electric heater and the aerosol-forming substrate.

The electric heater may comprise one or more heating elements over at least one aerosol-forming substrate. In a preferred embodiment, the electric heater may comprise one or more heating elements positioned between the base layer and the at least one aerosol-forming substrate. With this arrangement, heating of the aerosol-forming substrate and aerosol emission occur on opposite sides of the aerosol-forming substrate. This has been found to be particularly effective for aerosol-forming substrates comprising tobacco-containing materials. In a particular embodiment, the heater comprises one or more heating elements positioned adjacent to opposite sides of the aerosol-forming substrate. Preferably, the electric heater comprises a plurality of heating elements arranged to heat different portions of the aerosol-forming substrate. In a particular preferred embodiment, the at least one aerosol-forming substrate comprises a plurality of aerosol-forming substrates individually arranged on the base layer, and the electric heater comprises a plurality of heating elements, each arranged to heat a different one of the plurality of aerosol-forming substrates.

In use, the cartridge may be connected to a separate mouthpiece portion that allows the user to draw a flow of air through or adjacent the cartridge by sucking on the downstream end of the mouthpiece portion. For example, the mouthpiece portion may be provided as part of an aerosol-generating device that combines with the cartridge to form an aerosol-generating system. In such an embodiment, the cartridge may include a flange for attaching a removable mouthpiece portion. In certain preferred embodiments, the cartridge further comprises an integral mouthpiece portion. In such an embodiment, the cartridge is preferably arranged such that the aspiration resistance at the downstream end of the mouthpiece portion is from about 50 mmWG to about 130 mmWG, preferably from about 80 mmWG to about 120 mmWG, more preferably from about 90 mmWG to about 110 mmWG, and most preferably from about 95 mmWG to about 105 mmWG. As used herein, the term “pump resistance” refers to the pressure required to force air through the full length of an object under test at a rate of 17.5 ml/second at 22°C and 101 kPa (760 Torr), typically expressed in units of millimetres water gauge (mmWG) and measured in accordance with ISO 6565:2011.

In any of the embodiments described above, the aerosol-forming cartridge may include a data storage device configured to transmit data to the aerosol-generating device when the aerosol-forming cartridge is coupled to the aerosol-generating device. The data stored in the aerosol-forming cartridge may include at least one of the type of aerosol-forming cartridge, the manufacturer, the date and time of manufacture, the production batch number, the heating profile, and an indication of whether the aerosol-forming cartridge has been previously used.

In addition to the data storage device, or as an alternative to the data storage device, the aerosol-forming cartridge may include an electrical load configured to be electrically connected to the aerosol-generating device when the aerosol-forming cartridge is coupled to the aerosol-generating device. The electrical load may include at least one of a resistive load, a capacitive load, and an inductive load. The aerosol-generating device may be configured to control the supply of current to the cartridge based at least in part on the measured electrical load. Thus, the electrical load may be used to identify the type of cartridge.

In a particularly preferred embodiment, at least one electrical load comprises a resistive electric heater. Utilizing the heater itself as a resistive load eliminates the need for a separate, dedicated electrical load that would otherwise be provided specifically to distinguish different cartridges.

The cartridge may include electrical contacts to provide an electrical connection between the cartridge and an aerosol-generating device that may be coupled to the cartridge.

The electrical contacts may be accessible from the exterior of the cartridge. The electrical contacts may be located along one or more edges of the cartridge. In certain embodiments, the electrical contacts may be located along a side edge of the cartridge. For example, the electrical contacts may be located along the upstream edge of the cartridge. Alternatively, or additionally, the electrical contacts may be located along one longitudinal edge of the cartridge.

The electrical contacts may include power contacts for supplying power to the cartridge, as well as data contacts for transferring data to or from the cartridge, or in both directions.

The electrical contacts may have any shape. The electrical contacts may be substantially flat. Advantageously, substantially flat electrical contacts have been found to be more reliable in establishing electrical connections and easier to manufacture. Preferably, the electrical contacts comprise a portion of a standardized electrical connection, including but not limited to a USB-A, USB-B, USB-mini, USB-micro, SD, miniSD, or microSD type connection. Preferably, the electrical contacts comprise a portion of a standardized electrical connection, including but not limited to a USB-A, USB-B, USB-mini, USB-micro, SD, miniSD, or microSD type connection. As used herein, the term “standardized electrical connection” refers to an electrical connection specified in an industry standard.

The electrical contacts may be formed integrally with the electrical circuit. In a preferred specific embodiment, the cartridge includes an electric heater to which the electrical contacts are connected. In such an embodiment, the electric heater may include an electrically insulating foil on which the electrical contacts and one or more heating elements are arranged.

In certain embodiments, the cartridge may comprise a cover layer secured to the base layer and over at least a portion of the at least one aerosol-forming substrate. Advantageously, the cover layer can hold the at least one aerosol-forming substrate in place on the base layer. The cover layer can be secured to the base layer because it is integrally formed with the base layer. Alternatively, the cover layer may be a separate component secured directly to the base layer or indirectly via one or more intermediate layers or components. The aerosol emitted by the aerosol-forming substrate can pass through one or more openings in the cover layer, the base layer, or both. The cover layer may have at least one gas-permeable window to allow the aerosol emitted by the aerosol-forming substrate to pass through the cover layer. The gas-permeable window may be substantially open. Alternatively, the gas-permeable window may comprise a perforated membrane or grid extending over the openings of the cover layer. The grid may have any configuration, such as a horizontal grid, a vertical grid, or a mesh grid. The cover layer may form a seal with the base layer. The cover layer may form a sealing bond with the base layer. The cover layer may include a polymer coating that forms a seal between the cover layer and the base layer at least when the cover layer is secured to the base layer.

The aerosol-forming cartridge may comprise a protective foil positioned over at least a portion of at least one aerosol-forming substrate. The protective foil may be gas-impermeable. The protective foil may be positioned to hermetically seal the aerosol-forming substrate within the cartridge. As used herein, the term “hermetically sealing” means that the weight of volatile compounds within the aerosol-forming substrate changes by less than 2% over a two-week period, preferably over a two-month period, and more preferably over a two-year period. If the base layer comprises at least one cavity containing the aerosol-forming substrate, the protective foil may be positioned to block one or more of the cavities. The protective foil may be at least partially removable to expose at least one aerosol-forming substrate. Preferably, the protective foil is removable. If the base layer comprises a plurality of cavities containing a plurality of aerosol-forming substrates, the protective foil may be stepwise removable to selectively open one or more of the aerosol-forming substrates. For example, the protective foil may include one or more removable portions, each of which is positioned to expose one or more cavities when removed from the remainder of the protective foil. Alternatively, or additionally, the protective foil may be affixed such that the required removal force varies between various removal steps as an indication to the user. For example, the required removal force may increase between adjacent steps, so that the user must intentionally pull harder on the protective foil to continue removing it. This may be achieved by any suitable means. For example, the required removal force may be varied by changing the type, amount, or shape of the adhesive layer, or by changing the shape or amount of the bond line to which the protective foil is affixed.

The protective foil may be removably attached to the base layer, either directly or indirectly via one or more intermediate components. If the cartridge includes a cover layer as described above, the protective foil may be removably attached to the cover layer. If the cover layer has one or more gas permeable windows, the protective foil may extend across and block one or more of the gas permeable windows. The protective foil may be removably attached by any suitable method, for example, using an adhesive. The protective foil may be removably attached by ultrasonic bonding. The protective foil may be removably attached by ultrasonic bonding along a seam. The seam may be continuous. The seam may include two or more continuous seams arranged side by side. With this arrangement, the seal may be maintained as long as at least one of the seams remains intact.

The protective foil may be a flexible film. The protective foil may comprise any suitable material or materials. For example, the protective foil may comprise a polymer foil. The polymer foil may comprise any suitable material, such as, but not limited to, one or more of polyimide (PI), polyether ether ketone (PEEK), polyether ketone (PEK), or polyaryletherketone (PAEK) such as polyetherketoneetherketoneketone (PEKEKK), or a fluoropolymer such as polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), ethylene tetrafluoroethylene (ETFE), PVDFELS, or fluorinated ethylene propylene (FEP). The protective foil may comprise multiple layers of polymer foil.

An aerosol-forming cartridge may include an air inlet and an air outlet connected by an air flow channel in fluid communication with an aerosol-forming substrate when the cartridge is in use. The air flow channel may have an interior wall having one or more flow-disturbing devices arranged to create a turbulent boundary layer in the flow of air drawn through the air flow channel. In some embodiments, the flow-disturbing devices include one or more dimples or undulations on the interior wall.

According to a second aspect of the present invention, there is provided an electrically operated aerosol-forming system comprising an aerosol-generating device, an aerosol-forming cartridge as described in any of the embodiments above, and an electric vaporizer for vaporizing at least one aerosol-forming substrate, the device comprising: a body defining a slot-shaped receiving portion for removably receiving the aerosol-forming cartridge; and a power supply for supplying power to the vaporizer.

According to a third aspect of the present invention, there is provided a method of manufacturing an aerosol-forming cartridge for use in an electrically operated aerosol-generating system, the method comprising the steps of: providing a base layer on an assembly line; and placing at least one aerosol-forming substrate on the base layer such that the base layer and the at least one aerosol-forming substrate are in contact with each other at a substantially planar contact surface, wherein the aerosol-forming substrate comprises a tobacco-containing material having volatile tobacco flavor compounds that are released from the aerosol-forming substrate when heated.

The base layer may be formed as a single component. Alternatively, the base layer may comprise multiple layers or components that combine to form the base layer. The base layer may have a substantially planar top surface, and the step of disposing at least one aerosol-forming substrate on the base layer may be performed by disposing the aerosol-forming substrate on the substantially planar top surface.

In certain preferred embodiments, the method further comprises forming at least one cavity in the base layer, wherein the step of disposing at least one aerosol-forming substrate on the base layer is performed by disposing at least one aerosol-forming substrate in the at least one cavity. The cavity may be pre-formed in the base layer. In certain embodiments, the base layer comprises one or more molded parts, and the cavity is formed by a mold from which the one or more molded parts are made. In such embodiments, the base layer may be injection molded. Alternatively, the cavity may be formed in an existing base layer part by thermoforming or cold forming. The cavity may be formed in an existing base layer part using mechanical action, applied pressure, under vacuum, or any combination thereof. In certain embodiments, the step of providing the base layer comprises supplying a base layer foil web to an assembly line, and the step of forming at least one cavity in the base layer is performed by thermoforming or cold forming a bubble into the base layer foil web.

The method further comprises the step of providing a vaporizer for vaporizing at least one aerosol-forming substrate when the cartridge is used. For example, the vaporizer may comprise an electric heater attached to the base layer. In certain embodiments, the method further comprises the step of attaching the electric heater to the base layer such that the electric heater and the base layer contact each other at a contact surface that is substantially planar and substantially parallel to the contact surface between the base layer and the at least one aerosol-forming substrate. The electric heater may be attached directly to the base layer or indirectly through one or more intermediate components. The electric heater may be attached by any suitable method such as laminating, bonding, gluing, or mechanically securing such that it is received in place by other components of the cartridge.

The electric heater may be pre-formed as individual components and placed in the cartridge. In certain embodiments, the step of attaching the electric heater is performed by feeding the electric heater foil web from a bobbin to an assembly line and cutting the electric heater foil web transversely to form individual electric heaters. As used herein, the term “transversely” refers to a direction substantially perpendicular to the direction of component flow on the assembly line. The electric heater foil may include one or more electrically conductive layers, such as aluminum foil, from which, for example, one or more heating elements may be cut into the foil to form a heater. In certain embodiments, the electric heater foil web comprises an electrically insulating substrate foil web having a plurality of heating elements attached thereto. The electrically insulating substrate foil may include one or more polymeric foil electrically insulating layers. The polymer foil may comprise any suitable material, including but not limited to one or more of polyimide (PI), polyether ether ketone (PEEK), polyether ketone (PEK), or polyaryletherketone (PAEK) such as polyetherketoneetherketoneketone (PEKEKK), or a fluoropolymer such as polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), ethylene tetrafluoroethylene (ETFE), PVDFELS, or fluorinated ethylene propylene (FEP). In one particular embodiment, the electric heater foil comprises a stainless steel heating element sandwiched between two layers of polymer foil.

The base layer can be formed using any suitable manufacturing method. In certain embodiments, each base layer is formed of one or more of an injection molded polymeric material, such as, but not limited to, a polyaryletherketone (PAEK) such as polyether ether ketone (PEEK), polyether ketone (PEK), or {ut}polyetherketoneetherketoneketone {ut} (PEKEKK), a polyphenylene sulfide such as polyphenylene sulfide (PPS), a polyarylsulfone such as polychlorotrifluoroethene (PCTFE or PTFCE), polysulfone (PSU), polyphenylsulfone (PPSF or PPSU), polyethersulfone (PES), or polyethyleneimine (PEI), or a fluoropolymer such as polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), ethylene tetrafluoroethylene (ETFE), PVDFELS, or fluorinated ethylene propylene (FEP).

Alternatively, the step of providing the base layer comprises feeding the base layer foil web from a bobbin to an assembly line and cutting the base layer foil web transversely to form individual base layers. Alternatively, or additionally, the step of providing the base layer may comprise providing a substrate foil web and an intermediate foil web, attaching the substrate foil web and the intermediate foil web to each other to form the base layer foil web, and cutting the base layer foil web transversely to form the individual base layers. The substrate foil web may comprise a portion of an electric heater foil web. In such embodiments, the method may comprise attaching an electric heater to the base layer, wherein the substrate foil web is formed by an electrically insulating substrate foil web having a plurality of heating elements attached thereto. The base layer foil web may comprise any suitable material or materials. For example, the base layer foil web may comprise one or more polymeric foil layers. The polymer foil may comprise any suitable material, including but not limited to one or more of polyimide (PI), polyether ether ketone (PEEK), polyether ketone (PEK), or polyaryletherketone (PAEK) such as polyetherketoneetherketoneketone (PEKEKK), or a fluoropolymer such as polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), ethylene tetrafluoroethylene (ETFE), PVDFELS, or fluorinated ethylene propylene (FEP).

The method may further comprise the step of providing a cover layer over at least one aerosol-forming substrate and attaching the cover layer to the base layer. Advantageously, the cover layer is positioned to hold the at least one aerosol-forming substrate in place on the base layer. In certain embodiments, the cover layer is formed from an injection-molded polymer. In such embodiments, the cover layer may comprise any suitable material or materials. For example, each base layer can be formed of one or more of an injection molded polymeric material, such as, but not limited to, a polyaryletherketone (PAEK) such as polyether ether ketone (PEEK), polyether ketone (PEK), or {ut}polyetherketoneetherketoneketone {ut} (PEKEKK), a polyphenylene sulfide such as polyphenylene sulfide (PPS), a polyarylsulfone such as polychlorotrifluoroethene (PCTFE or PTFCE), polysulfone (PSU), polyphenylsulfone (PPSF or PPSU), polyethersulfone (PES), or polyethyleneimine (PEI), or a fluoropolymer such as polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), ethylene tetrafluoroethylene (ETFE), PVDFELS, or fluorinated ethylene propylene (FEP).

Alternatively, the step of providing a cover layer may comprise unwinding a cover layer foil web from a bobbin and attaching the cover layer foil to a base layer foil. The cover layer foil may be attached to the base layer foil by any suitable method, for example, by bonding. The cover layer foil web may comprise any suitable material or materials. For example, the cover layer foil web may comprise one or more polymer foil layers. The polymer foil may comprise one or more of any suitable material, such as, but not limited to, polyimide (PI), polyether ether ketone (PEEK), polyether ketone (PEK), or polyaryletherketone (PAEK) such as polyetherketoneetherketoneketone (PEKEKK), or a fluoropolymer such as polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), ethylene tetrafluoroethylene (ETFE), PVDFELS, or fluorinated ethylene propylene (FEP).

The method may further comprise the step of providing a protective foil over at least one aerosol-forming substrate to limit the release of volatile compounds from the aerosol-forming substrate. The protective foil may be positioned to hermetically seal the aerosol-forming substrate within the cartridge. The step of providing the protective foil may comprise unwinding a web of protective foil from a bobbin, and attaching the protective foil to the base layer, either directly or indirectly via one or more intermediate layers. The protective foil may be attached to the base layer foil by any suitable method, for example, by bonding. The protective foil may comprise any suitable material or materials. For example, the protective foil may comprise one or more polymeric foil layers. The polymer foil may comprise any suitable material, including but not limited to one or more of polyimide (PI), polyether ether ketone (PEEK), polyether ketone (PEK), or polyaryletherketone (PAEK) such as polyetherketoneetherketoneketone (PEKEKK), or a fluoropolymer such as polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), ethylene tetrafluoroethylene (ETFE), PVDFELS, or fluorinated ethylene propylene (FEP).

The method may further comprise the step of providing a top cover attached to the base layer and over the aerosol-forming substrate. The top cover may include an air inlet and an air outlet connected by airflow channels. The top cover may be formed as a single piece. Alternatively, the top cover may comprise multiple layers or pieces that join to form the top cover. The top cover may have a substantially planar top surface. In certain preferred embodiments, the method further comprises the step of forming at least one cavity in the top cover to at least partially define the airflow channel. The cavity may be pre-formed in the top cover. In certain embodiments, the top cover comprises one or more molded parts, the cavity being formed by a mold from which the one or more molded parts are made. In such embodiments, the top cover may be injection molded. Alternatively, the cavity may be formed in an existing top cover part by thermoforming or cold forming. The cavity may be formed in an existing top cover part using mechanical action, applied pressure, under vacuum, or any combination thereof. In certain embodiments, the step of providing a top cover comprises the step of supplying a top cover foil web to an assembly line, wherein the step of forming at least one cavity in the top cover is performed by thermoforming or cold forming a bubble into the top cover foil web.

When one or more components of the cartridge are formed from one or more foil webs, the one or more foil webs may be of a single width. In other words, each web may have substantially the same width as each component of the cartridge formed using the web. In a preferred specific embodiment, the one or more foil webs may each have a width that is about 2 to about 50 times greater than the width of each component formed using the web. Advantageously, this allows multiple aerosol-forming cartridges to be manufactured in parallel.

When one or more components of the cartridge are formed from two or more foil webs, the two foil webs may be attached to each other by any suitable method, such as using an adhesive, bonding, fusing, or any combination thereof. In one particular embodiment, two or more layers of the cartridge are laminated together. In such an example, the two layers are pressed together, and one or both layers are partially melted, such as using heat, ultrasound, or both, to fuse the layers together.

The method may comprise the step of transporting cartridge components onto a conveyor. The conveyor may be a continuous conveyor, such as a conveyor belt. The conveyor may have a plurality of cavities for receiving one or more components of the cartridge during manufacture, thereby ensuring accurate placement of the components on the conveyor. The cavities may be arranged in two or more parallel rows. The cavities may be arranged in a grid. Advantageously, this allows a plurality of aerosol-forming cartridges to be manufactured in parallel. Alternatively, the conveyor may comprise one or more foil webs for manufacturing cartridges and for pulling them along an assembly line by a drive wheel or other drive means. For example, the conveyor may comprise a base layer foil web.

According to a fourth aspect of the present invention, a method for manufacturing an aerosol forming cartridge according to any of the embodiments described above is provided.

Although the invention has been described with reference to different embodiments, it is apparent that features described with respect to one embodiment of the invention may be applied to other embodiments of the invention.

Hereinafter, the present invention will be further described by way of example only with reference to the attached drawings.

Figures 1a and 1b illustrate an aerosol generating device (10) and a separate, removable aerosol forming cartridge (20), which together form an aerosol generating system. The device (10) is portable and has a size comparable to a conventional cigar or cigarette. The device (10) comprises a body (11) and a removable mouthpiece portion (12). The body (11) comprises a battery (13), such as a lithium iron phosphate battery, an electrical circuit (14), and a slot-shaped cavity (15). The mouthpiece portion (12) is fitted over the cartridge and connected to the body (11) by a detachable connecting means (not shown). The mouthpiece portion (12) is removable (as shown in Figure 1) to allow insertion and removal of the cartridge, and is connected to the body (11) when the system is to be used to generate an aerosol, as will be described. The mouthpiece portion (12) includes an air inlet (16) and an air outlet (17), each of which may include one or more orifices. In use, the user draws air from the air inlet (16) through the mouthpiece portion (12) to the air outlet (17) by sucking or puffing on the air outlet (17). The flow of air drawn through the mouthpiece portion (12) may pass through the cartridge (20) (as illustrated by the arrow marked “A” in FIG. 1B) or may also be drawn through one or more air flow channels of the cartridge (20) (as illustrated by the arrow marked “B” in FIG. 1B). The cavity (15) has a rectangular cross-section and is sized to accommodate at least a portion of the cartridge (20) such that the device (10) and the cartridge (20) are removably connected. As used herein, the term “removably connected” means that the device and the cartridge can be joined and separated from each other without significant damage to either.

Figure 1c schematically illustrates a connection between a device (10) and a cartridge (20) within a cavity (15), wherein the cartridge (20) is shown partially inserted and an arrow indicates the insertion direction. Electrical contacts (18) are provided along the sides and bottom of the cavity (15) to provide an electrical connection between the electrical circuit (14) and the battery (13) together with corresponding electrical contacts on the cartridge (20). Guide rails (19) are provided in the cavity (15) to assist in precise positioning of the cartridge (20) within the cavity (15).

Figures 2a and 2b illustrate a first embodiment of an aerosol-forming cartridge (220). The cartridge (220) is substantially flat and has a rectangular cross-section, although it may have any other suitable flat shape. The cartridge comprises a base layer (222), an aerosol-forming substrate (224) disposed on the base layer (222), a heater (226) positioned between the aerosol-forming substrate (224) and the base layer (222), a cover layer (228) secured to the base layer (222) and over the aerosol-forming substrate (224), a protective foil (230) over the cover layer (228), and a top cover (232) secured to the cover layer (228) and over the cover layer (228) and the protective foil (230). The base layer (222), the aerosol forming substrate (224), the heater (226), the cover layer (228), the protective foil (230), and the top cover (232) are all substantially flat and substantially parallel to each other. The contact surfaces between these individual components of the cartridge (220) are substantially flat and substantially parallel to each other.

The base layer (222) has a cavity (234) defined on its upper surface in which a heater (226) and an aerosol-forming substrate (224) are accommodated. The aerosol-forming substrate (224) comprises a tobacco-containing material having volatile flavor compounds that can be released from the aerosol-forming substrate (224) when heated by the heater (226). In this example, the aerosol-forming substrate (224) is a substantially flat rectangular block of cast tobacco leaves.

The heater (226) includes a heating element (236) connected to an electrical contact (238). In this example, the heating element (236) and the electrical contact (238) are integral, and the heater (226) is formed by stamping stainless steel. The base layer (222) has two contact openings (240) at the distal end from which the electrical contacts (238) extend. The electrical contacts (238) are accessible from the outside of the cartridge through the contact openings (240).

The cover layer (228) helps to hold the aerosol-forming substrate (224) in place on the base layer (222). The cover layer (228) has a transmissive window (242) formed by a mesh grid (244) extending across an opening (246) of the cover layer (228). In use, aerosol emitted by the aerosol-forming substrate (224) passes through the transmissive window (242). The cover layer (228) is sized to fit over the cavity (234) of the base layer (222). In this example, the cover layer (228) extends laterally beyond the cavity (234) and has substantially the same width and length as the base layer (222), such that the edges of the cover layer (228) and the base layer (222) are generally aligned.

A protective foil (230) is removably attached to the top of the cover layer (228) and over the transmissive window (242) to enclose the aerosol-forming substrate (224) within the cartridge (220). The protective foil (230) comprises a substantially impermeable sheet that is bonded to the cover layer (228) but is easily peelable. The sheet is bonded to the cover layer (228) along a continuous seam formed by two continuous seams arranged in parallel. The protective foil (230) serves to prevent substantial loss of volatile compounds from the aerosol-forming substrate (224) prior to use of the cartridge (220). In this example, the protective foil (230) is formed from a flexible multilayer polymer sheet. A tab (248) is provided at the free end of the protective foil (230) to allow a user to grasp the protective foil (230) and peel it over the transmissive window (242).

The tab (248) is formed by an extension of the protective foil (230) and extends beyond the edge of the top cover (232). To facilitate removal, the protective foil (230) is folded over itself at the transverse fold line (249) so that the protective foil (230) is divided into a first portion (230A) attached to the cover layer (228) by a continuous seam and a second portion (230B) extending longitudinally from the fold line (249) to the tab (248). The second portion (230B) lies flat with respect to the first portion (230A), so that the first and second portions (230A, 230B) are substantially coplanar. With this arrangement, the tab (248) can be pulled longitudinally to remove the protective foil (230) and peel off the first portion (230A) from the cover layer (228) at the fold line (249).

Although bonding is described as a method of securing a removable protective foil (230) to a cover layer (228), it will be apparent to those skilled in the art that other methods well known to those skilled in the art may also be used, including but not limited to heat sealing or adhesives, provided that the protective foil (230) can be easily removed by the consumer.

The upper cover (232) is hollow and includes an air inlet (250) at its distal end and an air outlet (not shown) at its proximal end. The air inlet (250) and the air outlet are connected by an air flow channel (not shown) defined between an inner wall surface (not shown) of the upper cover (232) and the lower cover layer (228).

In use, the protective foil (230) is removed by pulling the tab (248) longitudinally away from the cartridge (220). Once the protective foil (230) is removed, the aerosol-forming substrate (224) is in fluid communication with the airflow channels through the transmissive windows (242) of the cover layer (228). The cartridge (220) is then inserted into an aerosol-generating device, as illustrated in FIGS. 1A and 1B , such that the electrical contacts (238) are connected to corresponding electrical contacts within the cavity of the device. The device then powers the heater (226) of the cartridge to emit aerosol from the aerosol-forming substrate. When the user puffs or draws on the mouthpiece portion of the device, air is drawn from the air inlet of the mouthpiece through the airflow channels of the top cover and into the air inlet (250) of the top cover, where the air mixes with the aerosol. The air and aerosol mixture is then sucked into the mouthpiece portion through the air outlet of the cartridge (220).

Once the aerosol forming agent (224) is consumed by the consumer, the cartridge is removed from the cavity of the device and replaced.

Figures 3a and 3b illustrate a second embodiment of an aerosol-forming cartridge (320). In this example, the cartridge (320) is substantially flat and has a rectangular cross-section, although it may have any other suitable flat shape. The cartridge comprises a base layer (322) formed from an intermediate layer (323) and a heater (326) secured to and disposed beneath the intermediate layer (323). The cartridge also comprises a plurality of aerosol-forming substrates (324) disposed on the base layer (322), a cover layer (328) secured to the base layer (322) and over the aerosol-forming substrate (324), a protective foil (330) over the cover layer (328), and a top cover (332) secured to the cover layer (328) and over the cover layer (328) and the protective foil (330). The intermediate layer (323), the aerosol forming substrate (324), the heater (326), the cover layer (328), the protective foil (330), and the top cover (332) are all substantially flat and substantially parallel to one another. Any contact surface between any two of these components (320) is substantially flat and substantially parallel.

The intermediate layer (323) has a plurality of cavities (334) extending through its thickness, the lower ends of which are closed by a heater (326). An aerosol-forming substrate (324) is accommodated within the plurality of cavities. In this example, the cavities (334) are substantially rectangular and are arranged with their long sides substantially perpendicular to the longitudinal axis of the cartridge (320). Each aerosol-forming substrate (324) comprises a tobacco-containing material having volatile flavor compounds that are capable of being released when heated by the heater (326). In this example, each aerosol-forming substrate is a substantially flat rectangular block of cast tobacco leaves.

The heater (326) comprises a plurality of heating elements (336) connected to electrical contacts (338). In this example, the heater (326) is formed by arranging the electrical contacts (338) and the substantially rectangular heating elements (336) on an electrically insulating foil (337) such that each heating element (336) is positioned beneath an aerosol-forming substrate (324). The electrically insulating foil (337) is sized to extend across the width and length of each cavity (334) so as to block the bottom of the cavity (334). Since the heater (326) is the bottom layer of the cartridge (320), the electrical contacts (338) extend along the side edges of the electrically insulating foil (337) and are accessible from the outside of the cartridge from below. In this example, an electrical contact (338) is provided for each of the plurality of heating elements (336). Accordingly, each heating element (336) can be individually powered to individually heat each aerosol-forming substrate (324). This allows for sequential heating of the aerosol-forming substrates, for example, to heat a 'new' or previously unheated aerosol-forming substrate (324) for each given aerosol delivery operation. In other embodiments, the heater may be external, i.e., provided adjacent to the cartridge when inserted into the aerosol-generating device, rather than provided within the cartridge. In such an example, a thermally conductive substrate foil, such as aluminum foil, may be used in place of the heater.

The cover layer (328) helps to hold the aerosol-forming substrate (324) in place within the cavity (334) of the base layer (322). The cover layer (328) has a transmissive window (342) formed by a grid (344) extending across an opening (346) of the cover layer (328). In use, aerosol emitted by the aerosol-forming substrate (324) passes through the transmissive window (342). The cover layer (328) is sized to fit over the cavity (334) of the base layer (322). In this example, the cover layer (328) extends laterally beyond the cavity (334) and has substantially the same width and length as the base layer (322), such that the edges of the cover layer (328) and the base layer (322) are generally aligned.

A protective foil (330) is removably attached to the top of the cover layer (328) and over the transmissive window (342) to enclose the aerosol-forming substrate (324) within the cavity (334). The protective foil (330) comprises a substantially impermeable sheet that is bonded to the cover layer (328) but is easily peelable. The sheet is bonded to the cover layer (328) along a continuous seam formed by two continuous seams arranged in parallel. The protective foil (330) serves to prevent substantial loss of volatile compounds from the aerosol-forming substrate (324) prior to use of the cartridge (320). In this example, the protective foil (330) is formed from a flexible multilayer polymer sheet. A tab (348) is provided at the free end of the protective foil (330) to allow a user to grasp the protective foil (330) and peel it over the transmissive window (342). The tab (348) is formed by an extension of the protective foil (330) and extends beyond the edge of the top cover (332). To facilitate removal, the protective foil (330) is folded over itself at the transverse fold line (349) such that the protective foil (330) is divided into a first portion (330A) attached to the cover layer (328) by a continuous seam and a second portion (330B) extending longitudinally from the fold line (349) to the tab (348). The second portion (330B) lies flat against the first portion (330A) so that the first and second portions (330A, 330B) are substantially flush with each other. With this arrangement, the tab (348) can be pulled longitudinally to remove the protective foil (330), thereby peeling the first portion (330A) from the cover layer (328) at the fold line (349). Although bonding is described as a method of securing a removable protective foil (330) to a cover layer (328), it will be apparent to those skilled in the art that other methods well known to those skilled in the art may also be used, including but not limited to heat sealing or adhesives, provided that the protective foil (330) can be easily removed by the consumer.

The top cover (332) is hollow and includes a plurality of air inlets (350) toward its distal end and an air outlet (not shown) at its proximal end. The air inlets (350) and the air outlets are connected by an air flow channel (not shown) defined between an inner wall surface (not shown) of the top cover (332) and the lower cover layer (328).

In use, the protective foil (330) is removed by pulling the tab (348) longitudinally away from the cartridge (320). Once the protective foil (330) is removed, the aerosol-forming substrate (324) is in fluid communication with the airflow channels through the transmissive windows (342) of the cover layer (328). The cartridge (320) is then inserted into an aerosol-generating device, as illustrated in FIGS. 1A and 1B , such that the electrical contacts (338) are connected to corresponding electrical contacts within the cavity of the device. The device then powers the heater (326) of the cartridge to emit an aerosol from one or more aerosol-forming substrates. When the user puffs or draws on the mouthpiece portion of the device, air is drawn from the air inlet of the mouthpiece through the airflow channels of the top cover and into the air inlet (350) of the top cover, where the air mixes with the aerosol. The air and aerosol mixture is then inhaled through the air outlet of the cartridge (320) into the outlet of the mouthpiece portion.

Once the aerosol forming agent (324) is consumed by the consumer, the cartridge is removed from the cavity of the device and replaced.

Figures 4a and 4b illustrate a third embodiment of an aerosol-forming cartridge (420). In this example, the cartridge (420) is substantially flat and has a rectangular cross-section, although it may have any other suitable flat shape. The cartridge comprises a base layer (422) formed from an intermediate layer (423) and a first heater (426) secured to and positioned beneath the intermediate layer (423). The cartridge also comprises an aerosol-forming substrate (424) disposed on the base layer (422) and a second heater (427) positioned above and secured to the top of the base layer (422). The intermediate layer (422), the aerosol-forming substrate (424), and the first and second heaters (426, 427) are all substantially flat and substantially parallel to one another. Any two contact surfaces between these components (420) are substantially planar and substantially parallel to one another.

The intermediate layer (423) has a cavity (434) extending through its thickness, the lower end of which is closed by a first heater (426). An aerosol-forming substrate (424) is accommodated within the cavity (434). In this example, the cavity (434) is substantially rectangular, with its long side being arranged substantially parallel to the longitudinal axis of the cartridge (420). The aerosol-forming substrate (424) comprises a tobacco-containing material having volatile flavor compounds that can be released when heated by the first and second heaters (426, 427). In this example, the aerosol-forming substrate is a substantially flat rectangular block of cast tobacco leaves.

The first and second heaters (426, 427) each include a plurality of heating elements (436) connected to electrical contacts (438). In this example, the heaters (426, 427) are formed by arranging the electrical contacts (438) and the heating elements (436) on electrically insulating foils (437), respectively. Each electrically insulating foil (437) is sized to extend across the width and length of each cavity (434). Accordingly, the first and second heaters (426) block the top and bottom of the cavity (434) and help maintain the aerosol-forming substrate (424) within the cavity (434). By making the thickness of the base layer (422) substantially the same as the thickness of the aerosol-forming substrate, the aerosol-forming substrate (424) can be firmly received within the cavity (434).

The electrical contacts (438) extend along the side edges of the electrically insulating foil (437). The electrical contacts of the first heater are accessible from the exterior of the cartridge from below, and the electrical contacts of the second heater are accessible from the exterior of the cartridge from above. The electrically insulating foil (437) of one or both of the first and second heaters (426, 427) is perforated to allow the aerosol emitted by the aerosol-forming substrate (424) to pass through the first and second heaters (426, 427). While the heaters (426, 427) are described as being perforated, one or both may instead include one or more gas-permeable windows. It will be apparent that it is sufficient for only one of the heaters (426, 427) to be perforated to the aerosol.

In use, the cartridge (420) is inserted into an aerosol generating device, as illustrated in FIGS. 1A and 1B, such that the electrical contacts (438) are connected to corresponding electrical contacts within the cavity of the device. The device then supplies power to the first and second heaters (426) to emit aerosol from the aerosol-forming substrate. When a user puffs or draws air from the mouthpiece portion of the device, air is drawn in through the mouthpiece portion from the air inlet of the mouthpiece, where the air is mixed with the aerosol. The air-aerosol mixture is then inhaled through the outlet of the mouthpiece portion.

Once the aerosol forming agent (424) is consumed by the consumer, the cartridge is removed from the cavity of the device and replaced.

Figures 5 and 6 illustrate schematic diagrams of the manufacturing processes for manufacturing the aerosol-forming cartridges of Figures 2a, 2b and 3a, 3b. In both processes described, the cartridges are assembled "vertically" at various stations along the assembly line as the cartridge components are conveyed along the manufacturing line. The term "vertically manufactured" refers to the fact that the cartridge components are arranged vertically and sequentially one above the other, typically starting with the lowest component and then the next component on top, ending with the top component of the cartridge, to form the cartridge as it moves along the conveyor. The contact surfaces between adjacent components are substantially planar and substantially parallel. With this approach, only vertical assembly operations are required. Therefore, more complex assembly operations, such as rotation or multiple translational movements, are not required when forming the cartridge.

FIG. 5 illustrates a schematic diagram of a manufacturing process for manufacturing the aerosol forming cartridge (220) of FIGS. 2a and 2b using an assembly line (500) having several different stations.

At a first station (510), individual injection molded base layers (222) are fed onto a conveyor (512), as indicated by an arrow, by a first automatic placement device (514), such as a pick-and-place machine. The conveyor (512) is a continuous belt having a plurality of cavities (not shown) on its upper surface for receiving the base layers and ensuring that the base layers are accurately placed on the conveyor (512). The cavities may be arranged in a grid, and the first automatic placement device (514) may be arranged to place the plurality of base layers into the cavities in a single operation, so that multiple cartridges can be manufactured simultaneously. Although applicable to multiple cartridges, the following description of the process refers to the manufacture of individual cartridges.

At the second station (520), an electric heater foil web (522) is fed from a bobbin (524) to a conveyor (512), and individual electric heaters (226) are cut from the foil web by a cutting device (526) and placed in cavities (234) on the top surface of the base layer by a second automatic placement device (528). In this step, the electric heaters are placed such that their electrical contacts (238) align with the contact openings (240) of the base layer. In this example, the electric heater foil web comprises an electrically conductive foil, such as stainless steel, which is stamped by the cutting device (526) to form the electric heating elements (236) and the electrical contacts (238).

At the third station (530), an aerosol-forming substrate (224) is supplied to the conveyor (512) by a third automatic placement device (532), such as a pick-and-place machine, and placed in a cavity (234) on the upper surface of the base layer (222) and on top of the electric heater (226). In this example, the aerosol-forming substrate comprises a solid substrate. In an example where the aerosol-forming substrate comprises a liquid substrate absorbed into a porous carrier, the porous carrier is first placed in the cavity by the third automatic placement device (532), and then the liquid substrate is dispensed onto the porous carrier using an automatic vertical dosing and filling device (not shown).

At the fourth station (540), an injection molded cover layer (228) is supplied to the conveyor (512) by the fourth automatic placement device (542) and placed over the base layer (222), the aerosol forming substrate (224), and the electric heater (226). Preferably, the cover layer is placed over the base layer such that at least a portion of its gas permeable window (242) is over at least a portion of the electric heater, thereby improving the flow of aerosol through the gas permeable window when the cartridge is used.

At the fifth station (550), the cover layer (228) is bonded to the base layer (222) using the first automatic ultrasonic bonding device (552).

At the sixth station (560), a protective foil web (562) is fed from a bobbin (564) onto a conveyor (512) and individual protective foils (230) are cut from the protective foil web. The protective foil is applied over the cover layer (228) such that the tabs (248) extend in the opposite direction to the assembled cartridge, i.e., toward the end of the cartridge (220) where the electrical contacts (640) are located. The protective foil is removably attached to the cover layer by ultrasonic bonding to form a continuous seam around the gas permeable window (242) of the cover layer, and the protective foil is then folded back against itself along the transverse fold line (249) such that the tabs extend beyond the cover layer in the direction shown in FIG. 2a. The cutting, bonding and folding steps may be performed by one machine (566) or by two or more separate devices.

At the seventh station (570), the injection molded top cover (232) is supplied to the conveyor (512) by a seventh automatic placement device (572), such as a pick-and-place machine, as indicated by the arrow.

At the 8th station (580), the upper cover (232) is bonded to the cover layer (228) by the second automatic ultrasonic bonding device (582), thereby completing the assembly of the cartridge.

The completed cartridges are then transported to a packaging machine (590), where they are combined with other completed cartridges and packaged for sale.

Figure 6 illustrates a schematic diagram of a manufacturing process for manufacturing the aerosol forming cartridge (320) of Figures 3a and 3b using an assembly line (600) having several different stations. At a first station (610), an electric heater foil web (612) is fed into the assembly line from a bobbin (614). The electric heater foil web (612) comprises an electrically insulating substrate having a plurality of electric heating elements and electrical contacts arranged thereon such that the electric heater foil web (612) can be cut to form individual electric heaters for individual cartridges. The electric heater foil web (612) can have a width that is several times the width of each completed cartridge, so that multiple cartridges can be manufactured simultaneously.

At the second station (620), the intermediate layer foil web (622) is fed from a bobbin (624) into the assembly line and onto the electric heater foil (612). The intermediate layer foil web (622) and the electric heater foil (612) are laminated together by a first laminating device (626) to form a base layer foil web (628). While any other suitable laminating process may be used, in this example, the intermediate layer foil web (622) and the electric heater foil web (612) are pressed together in the first laminating device (626) and heated to fuse the two webs together. Although the openings may be cut after unwinding from the bobbin (624) by a cutting device (not shown) positioned between the bobbin (624) and the first laminating device (626), in this example, the intermediate layer foil web (622) is pre-cut with a plurality of openings to form a cavity (334) in each intermediate layer (323) before being wound onto the bobbin (624).

At a third station (630), an aerosol-forming substrate (324) is supplied to the base layer foil (628) by a first automatic placement device (632), such as a pick-and-place machine, and placed into cavities (334) of the base layer foil (628). In an alternative embodiment where the aerosol-forming substrate comprises a slurry, a thin shield layer, also having a plurality of openings corresponding to the openings of the intermediate layer foil (622), may be removably attached to the upper surface of the intermediate layer foil web (622), for example, using an adhesive. After the slurry is dispensed into the cavities (334) by the first automatic placement device, which may in this case be an automatic vertical dosing and filling device (not shown), the shield layer is removed from the intermediate layer foil (622) to expose a clean upper surface for subsequent processing steps. In an alternative embodiment where the aerosol-forming substrate comprises a liquid substrate absorbed into a porous carrier, the porous carrier is first placed into the cavity by a first automatic placement device (632) and then the liquid substrate is applied to the porous carrier using an automatic vertical dosing and filling device (not shown) positioned behind the first automatic placement device (632).

At the fourth station (640), a cover layer foil web (642) is fed from a bobbin (644) into the assembly line and onto the base layer foil (628). The cover layer foil web (642) and the base layer foil web (628) are laminated together by a second laminating device (646). While any other suitable laminating process may be used, in this example, the base layer foil web (628) and the cover layer foil web (642) are pressed together in the second laminating device (646) and heated to fuse the two webs together. The cover layer foil web (642) comprises a polymer foil having a plurality of pre-formed grids for forming gas permeable windows (342) of the cover layer (328) of each cartridge (320).

At the fifth station (650), a protective foil web (652) is supplied from a bobbin (654) to the assembly line and onto the cover layer foil (642). The protective foil web (652) is pre-cut so that individual protective foils (330) can be separated from the protective foil web (652). The individual protective foils (330) are applied onto the cover layer foil web (642) such that each tab (348) extends in the opposite direction to the assembled cartridge, i.e., toward the upstream end of the cartridge (320) where the air inlet (350) is to be located. Each protective foil (330) is removably attached to the cover layer foil (642) by ultrasonic bonding to form a continuous seam around the gas permeable window (342) of the cover layer foil (642), and is folded back against itself along the transverse fold line (349) such that the tab (348) extends in the upstream direction, i.e., in the direction extended in FIG. 3a. The cutting, bonding and folding steps may be performed by one machine (656) or by two or more separate devices.

At the sixth station (660), the injection molded top cover (332) is fed into the assembly line and onto the protective foil (330) by a second automatic placement device (662), such as a pick-and-place machine.

At the 7th station (670), the upper cover (332) is bonded to the cover layer (328) by an automatic ultrasonic bonding device (672), thereby completing the assembly of the cartridge.

The completed cartridges are then transported to a packaging machine (690), where they are combined with other completed cartridges and packaged for sale.

In each of the aforementioned processes, any two or more foil webs may be indexed to ensure precise relative positioning of the various components of each cartridge. For example, the foil webs may have their indexed edges perforated.

The exemplary embodiments described above are merely illustrative and not limiting. In light of the exemplary embodiments described above, other implementations consistent with the exemplary embodiments will now be apparent to those skilled in the art.

10: Aerosol generating device
11: Body
12: Mouthpiece section
13: Battery
14: Electrical circuit
15: Joint
16: Air inlet
17: Air outlet
18: Electrical contacts
19: Rail
20,220,320,420: Aerosol forming cartridges
222,322,422: Base layer
224,324,424: Aerosol forming materials
226,326: Heater
228,328: Cover layer
230,330: Protective foil
230A,330A: Part 1
230B,330B: Part 2
232,332: Top cover
234,334,434: Joint
236,336,436: Heating element
238,338,438,640: Electrical contacts
240: Contact opening
242,342: Transparency
244: Mesh grid
248,348: Tap
249,349: Fold line
250,350: Air inlet
323,423: Intermediate
337,437: Electrical insulating material foil
346: Opening
426: First heater
427: Second heater
500,600: Assembly line
510,610: Station 1
512: Conveyor
514: First automatic exhaust device
520: Station 2
522,562,612,622,628,642,652: Foil Web
524,564,614,624,654: Bobbin
526: Cutting device
528: Second automatic exhaust device
530,630: Third Station
532: Third automatic exhaust device
540,640: 4th Station
542: 4th automatic exhaust system
550,650: Station 5
552: First automatic ultrasonic bonding device
560,660: Station 6
570,670: 7th Station
572: 7th Automatic Exhaust System
580: Station 8
582: Second automatic ultrasonic bonding device
590,690: Packaging machine
600: Line
620: Station 2
626: First layer device
646: Second layer device
662: Second Automatic Deployment Device
672: Automatic ultrasonic contact device

Claims (18)

An aerosol forming cartridge for use in an electrically operated aerosol generating system,
base layer; and
An aerosol-forming substrate disposed on the base layer, comprising at least one aerosol-forming substrate comprising a tobacco-containing material having volatile tobacco flavor compounds that can be released from the aerosol-forming substrate,
An aerosol-forming cartridge, wherein the base layer and the at least one aerosol-forming substrate are in contact at a substantially planar contact surface. An aerosol-forming cartridge according to claim 1, wherein one or both of the base layer and the at least one aerosol-forming substrate are substantially flat. An aerosol-forming cartridge according to claim 1 or 2, wherein the base layer comprises at least one cavity, and the at least one aerosol-forming substrate is accommodated in the at least one cavity. An aerosol-forming cartridge according to any one of claims 1 to 3, wherein the at least one aerosol-forming substrate comprises a plurality of aerosol-forming substrates individually arranged on the base layer. An aerosol-forming cartridge in claim 4, wherein the base layer comprises a plurality of cavities, and each of the plurality of aerosol-forming substrates is accommodated in one of the plurality of cavities. An aerosol-forming cartridge according to any one of claims 1 to 5, further comprising an electric heater comprising at least one heating element arranged to heat the at least one aerosol-forming substrate, wherein a contact surface between the electric heater and one or both of the base layer and the at least one aerosol-forming substrate is substantially planar and substantially parallel to the contact surface between the base layer and the at least one aerosol-forming substrate. An aerosol-forming cartridge in claim 6, wherein the at least one aerosol-forming substrate comprises a plurality of aerosol-forming substrates individually arranged on the base layer, and the electric heater comprises a plurality of heating elements each arranged to heat a different one of the plurality of aerosol-forming substrates. An aerosol-forming cartridge according to any one of claims 1 to 7, wherein the cartridge further comprises an integral mouthpiece portion. An aerosol-forming cartridge in claim 8, wherein the cartridge is arranged so that the suction resistance at the downstream end of the mouthpiece portion is about 50 mmWG to about 130 mmWG, preferably about 80 mmWG to about 120 mmWG, more preferably about 90 mmWG to about 110 mmWG, and most preferably about 95 mmWG to about 105 mmWG. An electrically operated aerosol forming system comprising an aerosol generating device, an aerosol forming cartridge according to any one of claims 1 to 9, and an electric vaporizer for vaporizing at least one aerosol forming substrate, wherein the aerosol generating device comprises:
A body defining a slot-shaped receiving portion for detachably receiving the aerosol forming cartridge; and
An electrically operated aerosol forming system comprising a power supply for supplying power to the vaporizer. A method of manufacturing an aerosol forming cartridge for use in an electrically operated aerosol generating system, comprising:
a step of providing a base layer; and
A method comprising the step of disposing at least one aerosol-forming substrate on the base layer such that the base layer and the at least one aerosol-forming substrate are joined at a substantially planar contact surface, wherein the aerosol-forming substrate comprises a tobacco-containing material having volatile tobacco flavor compounds that are released from the aerosol-forming substrate when heated. A method according to claim 11, further comprising the step of forming at least one cavity in the base layer, wherein the step of placing at least one aerosol-forming substrate on the base layer is performed by placing the at least one aerosol-forming substrate in the at least one cavity. A method according to claim 11 or 12, further comprising the step of attaching the electric heater to the base layer such that the electric heater and the base layer contact each other at a contact surface that is substantially planar and substantially parallel to the contact surface between the base layer and the at least one aerosol-forming substrate. In the 13th paragraph, the step of attaching the electric heater is performed by feeding the electric heater foil web from a bobbin to an assembly line and cutting the electric heater foil web transversely to form individual electric heaters. A method according to claim 14, wherein the electric heater foil web comprises an electrical insulating material foil web having a plurality of heating elements attached thereto. A method according to any one of claims 11 to 15, wherein the step of providing a base layer comprises feeding a base layer foil web from a bobbin to an assembly line and cutting the base layer foil web transversely to form individual base layers. A method according to any one of claims 14 to 16, wherein the electric heater foil web, or the base layer foil web, or both the electric heater foil web and the base layer foil web have a width greater than the width of each cartridge, preferably about 2 to about 50 times greater than the width of each cartridge, wherein a plurality of aerosol forming cartridges are made in parallel. A method according to any one of claims 14 to 17, wherein two or more foil webs from which the cartridge is manufactured are laminated together.